Developing High-Temperature Refractory Brick from Partially Laterized Khondalite Rock and Its Evaluation

Abstract

As a major waste product of bauxite mining, partially laterized khondalite (PLK) causes significant ecological damage. Despite rigorous research into sustainable alternatives to dumping, industries have yet to find an economically feasible solution for its large-scale reprocessing and industrial use. In this paper, refractory bricks were developed from partially laterized khondalite rock. Other materials including silica sand, fly ash, bentonite, and cement were used to increase the strength and strong bond formation. Ten refractory bricks were developed with varying material composition. It was found that brick with PLK (45%) + fly ash (25%) + silica sand (20%) + bentonite (2%) + cement (8%) showed the highest value (40.11 MPa) of compressive strength. The suitability of the refractory brick was examined with respect to its physical, mechanical, and thermal properties. The evaluation revealed that the properties are well suited for bulk density (2.54 g/cm3), high refractoriness (1400 degrees C), and high thermal shock resistance (17 cycles). Evaluation of the test results suggests that the mineral composition and thermal stability of the PLK rock sample are well suited for high-temperature refractory applications.